Expertise in welding

BOSAL's welding experts use the most advanced technologies to ensure that BOSAL remains a cutting edge exhaust supplier for the automotive industry.

BOSAL utilises a wide range of welding processes, covering thin wall materials and different material grades, with high gap filling capabilities. Laser welding and special MAG welding processes are widely used within the global organisation. 

Welding capability highlights

  • Laser welding
    • Thin wall
    • High grade
  • SP-MAG
  • HD-MAG 
  • Cold Metal Transfer (CMT).
  • Microscopic analysis
High precision welding- laser welding.

Focus on thin materials

BOSAL's state-of-the-art welding capabilities are focused on the use of thin materials, including ultrathin materials for BOSAL ECS innovations and BOSAL ECI advanced products.

International production standards

The production of BOSAL ECI products is carried out in accordance with international standards, including PED, ASME and ISO 3834-2.

Testing methods

For verification and validation of the welds, BOSAL uses in-house verification methods in its newly equipped welding laboratory. The verification methods include both non-destructive and destructive testing.

Two verification methods:

  • Marco-etch
  • Penetrant testing
Marco-etch laser welding verification method

Macro-etch 

The macro-etch is a cross-section of the weld showing the weld, the heat-affected zone and the materials.

Welds can be examined for:

  • Fusion
  • Shape
  • Penetration
  • Structure
  • Discontinuities (with magnification of up to 1000x)

Penetrant testing

Penetrant testing is used to find surface imperfections in the welded areaby means of a technique that uses a contrasting penetrant.

The penetrant test verifies:

  • Possible welding imperfections
  • Cracks that are invisible to the naked eye

Leader in welding innovation

As welding is at the core of the company's manufacturing processes, BOSAL keeps a close eye on the welding industry so that it can immediately implement improvements in its own production process and develop new processes for the future.

BOSAL has long been a leading player in the innovation of welding processes:

BOSAL introduced short arc MIG welding as early as the 1950s, before switching to the MAG welding process in 1965. This pulsed process reduced spatters and the heat input and improved the weld quality when compared to the short arc welding process.

After the introduction of the company's first welding robot in 1984, BOSAL quickly installed over 100 welding robots between 1984 and 1988 at its exhaust production facilities.


While laser welding processes were introduced before 2000, the welding robots were soon replaced by newer and faster models that could meet the demands of reduced wall thickness.
 

To optimise welding process control, BOSAL has been exclusively using robots with 1 CPU to control robot movement and the weld unit since 2005.